Soot Sensor

ABSTRACT

The present disclosure relates to exhaust gas emissions in motor vehicles. The teachings thereof may be embodied in soot sensors. For example, a soot sensor may include: a first electrode; a second electrode; an insulation body between the first electrode and the second electrode configured to allow soot particles to pass with a gas flow into a space defined between the first electrode and the second electrode; a meter evaluating a current between the first electrode and the second electrode resulting from an electrical voltage applied between the first electrode and the second electrode; and elements concentrating the electric field strength formed on at least one of a surface of the first electrode or a surface of the second electrode.

The invention relates to a soot sensor having a measurement electrode and having an outer electrode, wherein the measurement electrode and the outer electrode are electrically insulated with respect to one another by means of an insulation body.

The reduction of exhaust-gas emissions in motor vehicles is an important aim in the development of new motor vehicles. Therefore, combustion processes in internal combustion engines are thermodynamically optimized such that the efficiency of the internal combustion engine is considerably improved. In the automotive sector, increasing use is being made of diesel engines which, in modern embodiments, exhibit very high efficiency. The disadvantage of this combustion technology in relation to optimized Otto-cycle engines is however considerably increased soot emissions. Soot is particularly carcinogenic in particular owing to the concentration of polycyclic aromatic compounds, and various regulations have already been introduced in response to this. For example, exhaust-gas emissions standards with maximum limits for soot emissions have been enacted. To be able to realize blanket compliance with the exhaust-gas emissions standards for motor vehicles with diesel engines, there is a need to produce inexpensive sensors which reliably measure the soot content in the exhaust-gas flow of the motor vehicle.

Such soot sensors are used for measuring the soot presently being emitted, in order that the engine management system in a motor vehicle is provided, in a present driving situation, with information enabling it to reduce the emissions values using regulation-based adaptations. Furthermore, by means of the soot sensors, it is possible for active exhaust-gas purification by means of exhaust-gas soot filters to be initiated, or for exhaust-gas recirculation to the internal combustion engine to be implemented. In the case of soot filtering, regenerable filters are used which filter out a major part of the soot content from the exhaust gas. There is a need for soot sensors for detecting soot for the purposes of monitoring the function of the soot filters and controlling the regeneration cycles thereof.

For this purpose, a soot sensor may be positioned upstream, and/or a soot sensor may be positioned downstream, of the soot filter, which is also referred to as diesel particle filter.

The sensor positioned upstream of the diesel particle filter serves for increasing the system reliability and for ensuring operation of the diesel particle filter under optimum conditions. Since this is highly dependent on the soot quantity stored in the diesel particle filter, accurate measurement of the particle concentration upstream of the diesel particle filter system, in particular the determination of a high particle concentration upstream of the diesel particle filter, is of high importance.

A soot sensor positioned downstream of the diesel particle filter makes it possible for vehicle-internal diagnostics to be performed, and furthermore serves for ensuring correct operation of the exhaust-gas aftertreatment system.

The prior art presents various approaches for the detection of soot. An approach widely implemented in laboratories consists in using the light scatter through the soot particles. This approach is suitable for cumbersome measurement apparatuses. If it is sought to also implement this as a mobile sensor system in the exhaust tract, it must be noted that approaches for realizing an optical sensor in a motor vehicle are associated with very high costs. Furthermore, unresolved problems exist with regard to the fouling of the required optical window with combustion exhaust gases.

DE 195 36 705 A1 discloses a device for measuring soot particles, wherein an electric field is generated by means of the application of a constant electrical direct-current voltage between a casing electrode through which the gas flow passes and an inner electrode within said casing electrode, and the charge current for maintaining the constant direct-current voltage between casing electrode and inner electrode is measured. Good measurement results are obtained, in the context of the disclosure of DE 195 36 705 A1, if a direct-current voltage of 2000 to 3000 volts is used to generate the electric field.

In the case of these electrostatic soot sensors, the current between the two electrodes changes in a manner dependent on the soot concentration in the exhaust-gas flow. The currents that arise here are however relatively small, and the current intensity thereof lies in the range from pA to low nA values. Therefore, the entire measurement arrangement for said electrostatic soot sensors must be of very high-impedance design.

It is an object of the present invention to specify a soot sensor which outputs a considerably higher measurement current.

The object is achieved by means of the features of the independent claim.

By virtue of the fact that elements for concentrating the electric field strength are formed on the surface of the first electrode and/or on the surface of the second electrode, it is possible with a relatively low voltage to generate a high measurement current between the first electrode and the second electrode, which measurement current is proportional to the number of soot particles in the exhaust gas.

In one refinement of the invention, the first electrode is of rod-shaped form. This shape makes it possible to produce a very compact soot sensor. If the second electrode is of cylindrical form, a soot sensor can be produced in the case of which the cylindrical second electrode is formed concentrically around the rod-shaped first electrode. The soot sensor thus created has a long service life and a very compact design. In one refinement of the invention, the elements for concentrating the electric field strength are in the form of spike-like tips. Spike-like tips make it possible to realize a very high concentration of the electric field, whereby it is possible in a very small space to achieve high field strengths, which can lead to avalanche-like intensifications of the charge carriers between the first electrode and the second electrode.

If the elements for concentrating the electric field strength are in the form of triangular tips, it is possible to realize a very durable soot sensor, because the triangular tips are very robust components.

In one refinement of the invention, the elements for concentrating the electric field strength are in the form of grooves in the surface of the first electrode and/or in the surface of the second electrode. Grooves can be produced particularly easily in a surface and are thus particularly inexpensive.

If the elements for concentrating the electric field strength are formed by nanostructuring of the surface of the first electrode and/or of the surface of the second electrode, the electric fields and the electric field strengths associated therewith can be particularly easily predetermined and properly modeled, which leads to a soot sensor with particularly accurate measurement capabilities.

Below, the present invention will be discussed with reference to the appended drawings and on the basis of preferred embodiments. Said embodiments comprise soot sensors for use in a motor vehicle.

In the drawings:

FIG. 1 shows a soot sensor,

FIG. 2 shows a soot sensor according to the invention,

FIG. 3 shows a further embodiment of the soot sensor according to the invention,

FIG. 4 shows a further embodiment of the soot sensor known from FIG. 3,

FIG. 5 shows a further embodiment of the soot sensor according to the invention.

FIG. 1 shows a soot sensor 1. The soot sensor 1 is composed of a first electrode 2, which is arranged in the interior of a second electrode 3. The exhaust gas, which contains soot particles 4, of the internal combustion engine is situated between the first electrode 2 and the second electrode. It is sought to measure the concentration of the soot particles 4 in the exhaust gas by means of the soot sensor. In other words, it can be stated that it is sought to determine the soot content in the exhaust gas by means of the soot sensor. For this purpose, a measurement voltage is applied between the first electrode 2 and the second electrode 3 by the voltage supply 6. The first electrode 2 is electrically insulated with respect to the second electrode 3 by means of the insulation body 5. The insulation body 5 may be constructed as a disk composed of a ceramic material. Furthermore, it can be seen in FIG. 1 that an ohmic resistance 7 is connected between the voltage supply and the second electrode 3, which ohmic resistance exhibits high impedance in order to measure the relatively small currents that can form between the first electrode 2 and the second electrode 3 owing to the soot particles 4. The measurement of said currents is realized by means of the current measurement element 8, which is connected to evaluation electronics 9. Such soot sensors 1 are used for on-board diagnosis in motor vehicles with diesel engines.

The voltage that must be applied between the first electrode 2 and the second electrode 3 in order to obtain evaluable measurement currents is relatively high. Such a voltage may amount to 2 to 3 kV and is thus relatively cumbersome to monitor. It is therefore advantageous, in order to generate easily evaluable measurement currents, to use the embodiments according to the invention of the first electrode 2 and/or of the second electrode 3, as described below.

FIG. 2 shows a soot sensor 1 according to the invention with a first electrode 2 and with a second electrode 3. The first electrode 2 is electrically insulated with respect to the second electrode 3 by means of an insulation body 5, and an electrical voltage, which is generated by the electrical voltage supply 6, is applied between the first electrode 2 and the second electrode 3. It is sought to measure the concentration of the soot particles 4 in the exhaust gas by means of the soot sensor 1 according to the invention. It is thus also sought to determine the soot content in the exhaust gas by means of the soot sensor 1 according to the invention.

Soot particles 4 which are transported in an exhaust-gas flow from an internal combustion engine through an exhaust tail pipe can enter the soot sensor 1 which is integrated in the exhaust tail pipe. The soot particles 4 pass into an electric field which forms owing to the electrical voltage applied between the first electrode 2 and the second electrode 3. To generate an easily measurable electrical current between the first electrode 2 and the second electrode 3, elements 15 for concentrating the electric field strength are formed on the surface of the first electrode 2 and/or on the surface of the second electrode 3. In this example, the first electrode 2 is in the form of a rod-shaped threaded bar, wherein the elements 15 for concentrating the electric field strength are formed by the thread flights, between which triangular tips are formed. The electric field is concentrated at these tips, whereby the electric field strength becomes very high in the region of the tips. The intense increase in the electric field strength in the region of the tips can exceed the breakdown field strength of the gas in said region. In the event of the breakdown field strength of the gas being exceeded, electrically charged particles are formed which are accelerated in the direction of the opposite electrode and, owing to impact ionization events, lead to an avalanche-like formation of charge carriers. When said charge carrier avalanche reaches an electrode surface, a very high current can be measured, which can be easily evaluated and which is proportional to the number of charged particles in the exhaust gas.

FIG. 2 however also shows an ohmic resistance 7, which is advantageous in order to be able to measure, by means of the evaluation electronics 9, the electrical current that flows between the first electrode 2 and the second electrode 3. Furthermore, FIG. 2 shows a protective cap 10 which serves for the targeted guidance of the exhaust-gas flow through the soot sensor 1. The exhaust gases may for example into the soot sensor 1 through a first opening 11, where the soot content in the exhaust gas can be measured between the first electrode 2 and the second electrode 3. Thereafter, the exhaust-gas flow exits the soot sensor 1 through the second opening 12 formed in the second electrode 3, and is conducted back into the main exhaust-gas flow via the third opening 13.

FIG. 3 shows a further embodiment of the soot sensor 1 according to the invention. Here, the soot sensor 1 is of rotationally symmetrical form about a central axis 14. The first electrode 2 is in the form of a rod-shaped electrode. The cylindrical second electrode 3 is formed concentrically around the second electrode. The second electrode 3 is thus in the form of a hollow cylinder. The insulation body 5, which in this case is in the form of a disk, electrically separates the first electrode 2 from the second electrode 3. A voltage can be applied between the first electrode 2 and the second electrode 3 by means of the voltage supply 6. The elements 15 for field concentration formed on the inner surface of the second electrode 3 are in this case in the form of triangles. The tips of the triangles lead to a very high field strength in the region of the tips of the triangles. Owing to said high field strength, the breakdown field strength in the exhaust gas can be exceeded, whereby, owing to avalanche-like impact ionization, a high measurement current can be generated, which can be easily registered by means of the evaluation electronics 9.

FIG. 4 shows a further embodiment of the soot sensor 1 known from FIG. 3. The first electrode 2 is equipped with elements 15 for concentrating the electric field strength, which elements are in the form of spike-like tips. The second electrode 3, on its inner surface, has semicircular elements 15 for concentrating the electric field strength. A multiplicity of possible surface structures of the first electrode 2 and of the second electrode 3 are conceivable, whereby targeted modeling of the field distribution in the interior of the soot sensor 1 is possible.

FIG. 5 shows a further embodiment of the soot sensor 1 according to the invention. Here, both the first electrode 2 and the second electrode 3 are formed as rod-shaped elements. Triangular elements 15 for concentrating the electric field strength are formed both on the first electrode 2 and the second electrode 3. The first electrode 2 and the second electrode 3 are electrically insulated with respect to one another by means of the insulation body 5. A protective cap 10 is formed over the first electrode 2 and over the second electrode 3. The protective cap 10 again, by means of the first opening 11, the second opening 12 and the third opening 13, allows the exhaust gas and the soot particles to flow into the interior of the soot sensor 1 and thus also between the first electrode 2 and a second electrode 3. The second electrode 3 may, in the context of the disclosure of FIGS. 1 to 5, be in the form of a hollow cylinder. 

What is claimed is:
 1. A soot sensor comprising: a first electrode; a second electrode; an insulation body between the first electrode and the second electrode configured to allow soot particles to pass with a gas flow into a space defined between the first electrode and the second electrode; a meter evaluating a current between the first electrode and the second electrode resulting from an electrical voltage applied between the first electrode and the second electrode; and elements concentrating the electric field strength formed on at least one of a surface of the first electrode or a surface of the second electrode.
 2. The soot sensor as claimed in claim 1, wherein the first electrode comprises a rod-shape.
 3. The soot sensor as claimed in claim 1, wherein the second electrode comprises a cylindrical shape.
 4. The soot sensor as claimed in claim 2, wherein the cylindrical second electrode is arranged concentrically around a rod-shaped first electrode.
 5. The soot sensor as claimed in claim 1, wherein the elements comprise spike-like tips.
 6. The soot sensor as claimed in claim 1, wherein the elements comprise triangular tips.
 7. The soot sensor as claimed in claim 1, wherein the elements comprise grooves in one of the surfaces.
 8. The soot sensor as claimed in claim 1, wherein that the elements comprise nanostructures on the surface of the first electrode or the surface of the second electrode. 